product / model number afb2€¦ · the avalon afb2 vanadium flow battery is an integrated energy...

27
THIS DOCUMENT, SUBMITTED IN CONFIDENCE, CONTAINS PROPRIETARY INFORMATION WHICH SHALL NOT BE REPRODUCED OR TRANSFERRED TO OTHER DOCUMENTS OR DISCLOSED TO OTHERS OR USED FOR MANUFACTURING OR ANY OTHER PURPOSE WITHOUT PRIOR WRITTEN PERMISSION OF AVALON BATTERY CORPORATION. THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018 Commercial Confidential PRODUCT / MODEL NUMBER AFB2 DOCUMENT TITLE Installation and Operation Manual, DC Battery DOCUMENT NUMBER SPC00138 DOCUMENT LIFECYCLE ISSUED REVISION 004 TOTAL # of PAGES 27

Upload: others

Post on 31-May-2020

7 views

Category:

Documents


0 download

TRANSCRIPT

Page 1: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

THIS DOCUMENT, SUBMITTED IN CONFIDENCE, CONTAINS PROPRIETARY INFORMATION WHICH SHALL NOT BE REPRODUCED OR TRANSFERRED TO OTHER DOCUMENTS OR DISCLOSED TO OTHERS OR USED FOR MANUFACTURING OR ANY OTHER PURPOSE WITHOUT PRIOR WRITTEN PERMISSION OF AVALON BATTERY CORPORATION.

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

PRODUCT / MODEL NUMBER

AFB2 DOCUMENT TITLE

Installation and Operation Manual, DC Battery DOCUMENT NUMBER

SPC00138 DOCUMENT LIFECYCLE

ISSUED REVISION

004 TOTAL # of PAGES

27

Page 2: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 2 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

COPYRIGHT Unless stated otherwise, copyright in this document (including content and design) is owned by Avalon Battery Corporation or used under licence. You may not reproduce, adapt, modify, communicate to the public, reproduce or otherwise use any part of this document (in particular for commercial purposes) except as set out below, or otherwise with the express written permission from Avalon Battery Corporation. Copyright © Avalon Battery Corporation, 2018.

DISCLAIMER

Avalon Battery Corporation and its subsidiaries makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranty or merchantability or fitness for any particular purpose. Avalon Battery has made every effort to ensure that content within this manual is accurate but disclaims liability for any inaccuracies or omissions that may have occurred. Information in this document is subject to revision without notice.

TRADEMARK

Product names used in this manual are the properties of their respective owners and are acknowledged.

SUPPORT

For any additional support, please contact Avalon Battery at the following: Avalon Battery Corporation 426 17th Street, Suite 700 Oakland, CA 94612 Via email: [email protected] On the web: www.avalonbattery.com Phone: 604-563-2144

Page 3: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 3 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

1.0 Introduction The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of Avalon’s vanadium flow battery, electrical and controls system that provide a DC Battery source for DC coupled, grid interactive or microgrid energy provision and management.

Figure 1 – AFB2 Vanadium Flow Battery.

Page 4: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 4 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

1.1 Abbreviations AC Alternating current AHJ Authority having jurisdiction AWG American wire gauge BMC Battery management controller BMS Battery management software DC Direct current EMS Energy management system HVDC High voltage direct current NEC National Electrical Code NFPA National Fire Protection Association NPT National pipe taper PC Personal computer PCS Power conversion system PE Protective earth PPE Personal protective equipment PSU Power supply unit SDS Safety data sheet SOC State of charge

Page 5: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 5 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

1.2 Product Specifications

Battery Specifications Model AFB2.10 AFB2.5 Energy Storage Capacity, Rated 30 kWh Continuous DC Power, Max 11 kW 5.5 kW DC Power, Rated 10.5 kW 5.25 kW Energy Storage Duration, Nominal 3 hours 6 hours Energy Storage Ampacity, Nominal 55 Ah Operating Voltage, Nominal 550 DC V Energy Storage Capacity, Annual Degradation1 < 0.5% per year Battery Energy Efficiency, Round-Trip (DC) > 75% Energy Efficiency, Annual Degradation1 < 0.1% per year Discharge Voltage Range 440 to 600 DC V Charge Voltage Range 500 to 600 DC V Continuous Discharge / Charge Current, Rated 20 DC A 10 DC A Internal Fuse Rating 30 DC A 15 DC A

Physical

Battery Dimensions (L x W x H), not including Power Converter

1.77 m x 1.07 m x 1.79 m [69.7” x 42.3” x 70.4”]

Mass (flooded) 3000 kg [6600 lbs] Electrolyte Volume, Nominal 1460 L

Environmental Ambient Operating Temperature Range –5 to 45°C Extended Ambient Operating Temperature Range, with Optional Cold Weather Kit –25 to 45°C

Storage Temperature Range –25 to 50°C Cooling Integrated, forced air

Certification / Standard Compliance Safety UL 19732

1 On the basis of 130 full depth-of-discharge cycles per year 2 Pending

Page 6: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 6 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

1.3 Description Avalon’s AFB2 is a direct current (DC) energy storage system composed of components that comprise two key functions: the battery function which provides electrochemical energy storage and the electrical and controls function that responds to external power requests and provides the requested DC power.

1.3.1 Battery Function Housed within the enclosure of the system are all components of the battery, including the cell stack(s), electrolyte processing system, electrolyte storage (including the electrolyte) and the thermal management system. Integrated as part of the enclosure is a secondary containment vessel, lined with an electrolyte-resistant coating to prevent electrolyte from escaping the system in event of any internal leak. These components are accessed behind the removable plastic front Avalon cover and the internal metal access panel. Given the presence of potential hazards within the battery enclosure, only authorized personnel should ever access the inside of the battery enclosure.

1.3.2 Electrical and Controls Function Within the battery enclosure and located between the two stacks is a panel frame that houses the electrical and controls components. This panel frame houses two bi-directional DC-DC converters, the battery’s power supply unit (PSU) and the battery management controller (BMC). Given the presence of high voltage components within the enclosure, only authorized personnel should ever touch or service these components.

Figure 2 – Inside view of AFB2 battery compartment.

Figure 3 – Internal view of electrical components.

Page 7: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 7 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

2.0 Important Safety Instructions

SAVE THESE INSTRUCTIONS! This manual contains important instructions related to the installation, operation and maintenance of Avalon Battery’s AFB2. This manual should be retained throughout the life of the product. Product failures or decreases in performance resulting from an act in contravention of the operation manual shall be excluded from the product warranty.

Hazard voltages are present within the AFB2. Installation and maintenance should only be conducted by qualified personnel familiar with this manual and with proper precautions in place.

Hazardous voltages can remain on the battery even when fully disconnected. Proper precautions MUST be taken to avoid direct contact with HV & LV DC components AT ALL TIMES. A service event that requires potential exposure to one more DC components, shall only be undertaken by specially-training personnel with proper PPE.

Electrolyte is corrosive and acutely toxic. Avoid all contact with skin and eyes. When working with or conducting a procedure that results in potential exposure to electrolyte, all necessary personal protective equipment must be worn. This includes safety glasses, sleeves, gloves, lab coat or apron and may include boots and respirator.

During the course of charging and discharging or in a fault condition, flammable gases can be generated within the battery. Gas ventilation system must be properly installed where required. All necessary precautions MUST be taken when attempting to service within the battery or electrolyte tanks, this includes:

• personal flammability meters to safe gas levels – do not access or continue service if gas concentration above 25% LFL

• proper ventilation and purging

• non-sparking tools

Page 8: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 8 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

The following precautions shall be followed at all times:

• Installation shall conform to federal, state and local regulations regarding hazardous material.

• All personnel (installers, operators, etc.) that may come into contact with electrolyte must be trained and have read and are familiar with the safety data sheet (SDS) for electrolyte. Electrolyte SDS can be found in appendix of all manuals.

• All wiring connections to system shall be compatible with specifications identified in this document and completed in accordance with local codes and NFPA 70 (NEC).

• Electrical grounding shall be in accordance with code requirements & NFPA 70 (NEC).

• External electrical systems must be operated within the stated voltage, current and power limitation as stated on the product specs. The system is intended to be installed with a field installed Manual DC Disconnect.

• The system shall not be connected to any electrical equipment that is not explicitly called out in the manual or sales agreement. This includes installations or connections that in any way deviate from the procedures and connections explicitly allowed in the manual.

• System shall only be operated in accordance with this manual.

• The system shall not be operated outside of the stated environmental conditions.

• Air flow path shall be unrestricted, ensuring sufficient air flow to the system.

• The battery shall not be operated with any external enclosure panels removed. The enclosure panels protect against rain, dust and debris ingress, electric shock and electrolyte egress in the unlikely event of a leak.

• No person shall attempt to service, modify or alter the product (including software) in a way not explicitly allowed by this installation and operation manual or the service manual.

• Only authorized personnel should attempt to service the system. Personnel should be familiar with all product documentation prior to conducting service.

• Do not bypass or make any changes to plumbing or any electrical connections.

• Use extreme care when servicing the unit with tools to avoid accidental shorts.

• In the event of an electrolyte leak the system should be powered down via the DC disconnect. If uncontained, i.e. outside of secondary containment, measures must be taken to control and contain leak. Refer to site specific emergency response instructions completed in accordance with local, state and federal regulations.

• The system is not intended to be installed in a marine environment.

• Systems intended for outdoor use shall be mounted on a non-combustible surface, such as a concrete pad, that extends a minimum of 91.4cm (3ft) on all sides.

Page 9: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 9 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

3.0 Internal Protections The AFB2 includes primary self-protection functions described in the following sections. These functions are embedded with the battery internal hardware and protects the battery from mis-operation and potential damage.

3.1 Over-Current / High Voltage DC (HVDC) Fuse A fuse is located at the first connection point to the battery on the positive wiring to act as over-current protection on the high-voltage line. This is a replaceable midget-style fuse.

Voltage Rating Min. 600 DC V

Size 10 x 38 mm

Type Fast-blow

Current Rating

30 A (AFB2.10) 15 A (AFB2.5)

Examples

Littlefuse SPF030 / SPF015 Mersen HP10T30 / HP10T15

Figure 4 – Fuse details and location, adjacent to the landing distribution block for external HVDC wiring

3.2 Over-voltage The AFB2 possess multiple levels of overvoltage protection, with ultimate protection integrated within the DC-DC converters.

3.3 Over-charge Hardware protection has been built into the battery management controller (BMC) to prevent ensure over-charge.

3.4 Current Limiting Devices on Sub-components The motor drives and fan power supplies have current limiting hardware protection built into the controller for protection in the event of shorting of the pump motor or fan power cable harness.

3.5 Secondary Containment The AFB2 has integrated secondary containment built into the lower enclosure of the system, in the event of an internal system leak in the plumbing, stacks, or primary tanks. This containment consists of an internal coating of an elastomeric polyurethane coating on

Page 10: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 10 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

the inside of a continuously welded steel enclosure. This coating has proven chemical resistance to continuous exposure of concentrated acids including 50% sulfuric acid. The capacity of the secondary containment (including the primary tanks), is capable of holding in excess of 130% of AFB2 electrolyte capacity. In addition, all of the plumbing, stacks, and primary containment tank are designed within the footprint of the secondary containment so any leak is designed to remain within the secondary containment. In the event of an internal system leak (tanks, stack or plumbing), the tank level will eventually drop below the pump supply hose from the tank (nominally 5% electrolyte loss), at which point, the pumps will stop operating and a fault will be generated by the system.

Page 11: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 11 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

4.0 Unpacking Upon receiving the battery, the packaging shall be carefully inspected and any damage shall be noted and reported to the shipper and Avalon Battery before continuing with installation. All packaging materials shall be removed and properly disposed. All equipment shall be inspected for signs of damage. Avalon Cover panels are typically shipped on top of system and should be carefully removed and set aside until ready for installation. If received as components, components should be unpacked carefully and inspected for any signs of damage. Personal protective equipment (PPE), including eye protection and gloves should be worn while unpacking any electrolyte containing components (e.g. cell stacks) in event of any electrolyte leakage that may have occurred during transport. If any leaked electrolyte is found, installation shall be stopped and reported to Avalon Battery.

4.1 Shock & Tilt Detectors If installed on packaging or equipment, the state of the shock and tilt indicators should be recorded at the time of receiving the equipment from the shipper. A photo should be taken of each indicator and associated with the position of each. Any indication of excessive shock or tilt shall be immediately reported to Avalon Battery.

Page 12: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 12 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

5.0 Handling The AFB2 is designed to be handled with a fork lift using the pockets in the bottom of the enclosure or via an overhead crane using the lifting points shown in Figure 5. The AFB2 is shipped in upright position and MUST remain in an upright position while being moved or handled.

5.1.1 Overhead Crane To lift and/or move with a crane, the plastic cover panels shall be removed and attached to the roof of the unit. Lift the system by utilising four M10 hoist rings installed into the designated lifting lugs. Install four 2m (72’) lifting straps at each corner to hoist the battery.

The AFB2 is designed to be lifted and handled either via the fork lift pockets at the base or via the lifting points located at the mid-point of the battery. The top of the enclosure is NOT rated for lifting or strapping down and MUST NOT be used as lifting point.

Figure 5 – Overhead lift points and example lifting arrangement.

5.1.2 Forklift To lift and/or move with a forklift there are two jack pockets that must be used at the bottom of the enclosure. Ensure the battery is centered over the fork lift.

Never attempt to lift or jack at any point that is not the hoist hook mounts or jack pockets and always ensure lifting equipment is in good condition and sufficiently rated to carry the desired load

Page 13: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 13 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

Figure 6 – Example of battery being handled via fork lift pockets.

5.2 Components 5.2.1 Cell Stacks

If shipped as a separate component, cell stack(s) will be shipped in a crate and designed to be moved using a fork lift or pallet jack. To minimize potential handling damage, stacks should remain on the pallet they are shipped upon while being handled. Please see the service manual for information on stack installation or exchanges.

Flooded cell stacks weigh 120 kg each. Attempting to manually lift is NOT recommended.

5.2.2 Electrolyte If shipped as a separate component, electrolyte will be shipped in one or more UN recognized intermediate bulk container (IBC) totes. Proper precautions and equipment should be used to handle and move the totes. Please see the Service Manual for more information on electrolyte loading NOTE: The mass of a full 1000L tote is approximately 1400kg.

Electrolyte is corrosive and acutely toxic. Avoid all contact with skin and eyes. When working with or conducting a procedure that results in potential exposure to electrolyte, all necessary personal protective equipment must be worn. This includes safety glasses, sleeves, gloves, lab coat or apron and may include boots and respirator.

Page 14: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 14 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

6.0 Installation 6.1 Siting

Prior to installation, the installer must verify that planned installation is in compliance with local building and fire codes including necessary regulations related to hazardous material storage and batteries / flow batteries. This typically requires an approved permit from the authority having jurisdiction (AHJ). Refer to table below for installation siting requirements for battery installation. Local installation requirements shall supersede these guidelines where any conflict exists. Installers shall always consult with local AHJ for applicable requirements.

Risk of physical damage If system is in a high traffic location, physical protection (such as bollards, walls, etc.) shall be provided.

Surface load Surface shall be capable of supporting a minimum 60 kPa weight load

Grade Installation surface shall be level within 25 mm [1 in] per 2.44 m [8 ft]

Air flow Installation location shall be such that air flow to front air intake and rear panel exhaust is not obstructed. In addition, hot exhaust streams from other equipment should not directed towards air intake.

Indoor installation Indoor installations shall be in rooms with sufficient continuous ventilation to ensure hydrogen gas that may be evolved by the system shall not accumulate to beyond 25% of LFL. When continuous ventilation cannot be provided, an external vent line can be connected to the system to provide for direct ventilation. A minimum air exchange of 2 air changes per hour shall be provided to ensure proper cooling.

Service access A minimum of 0.92 m [36 inches] unobstructed area shall be reserved in the front of the battery. Any battery with power conversion system (PCS) mounted to the side shall provide required service access as defined by PCS manufacturer or local codes.

Table 1 – Siting requirements.

6.2 Anchoring The AFB2 is designed to be anchored to a concrete floor or pad. The design of the anchoring system shall be completed in advance and in accordance with applicable seismic

Page 15: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 15 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

and civil requirements, per site location. In completing such design, an analysis shall be conducted by an authorized professional engineer; including confirming sufficient bolt strengths, concrete / floor bearing load, etc. Always refer to local building authority to confirm such requirements. Anchoring of the system is designed to be done with typical floor anchors (such as Hilti® Concrete Anchors) or clamps. Anchors are to be drilled and installed after locating and placing the system. Alternative anchoring solutions, including mounting on driven piers or piles may be considered at customer’s discretion but should be reviewed and approved by Avalon before proceeding.

6.3 External Gas Vent The system requires air flow and ventilation in all installed locations. If the system is installed in a confined space with insufficient or non-continuous ventilation or otherwise requires an external gas vent, one can be installed and connected via the gas vent on the rear panel.

Care must be taken when routing any external gas vent lines to avoid liquid traps or other blockages from external material. Vent must also be routed away from sources of ignition or building air intakes.

6.4 Mounting the Antenna NOTE not all batteries will be shipped with an antenna installed. This is defined by the factory configuration. The antenna mount is shipped external to the battery in an upside-down orientation so that it does not stick above the top of the enclosure. Prior to installation of the antenna – the mounting bracket should be removed and turned around so that the antenna, when it is attached to the top of the bracket, as shown in Figure 7, sits above the highest point of the enclosure, and the bracket can be secured to the battery using the same two bolts it was shipped with. The antenna will either ship separately or be already mounted to the bracket. If shipped separately, the antenna should be mounted to the two screw-hole placements at the top of the antenna bracket. The antenna cable should be pulled through the cable gland and the cable gland should be tightened. The BMC controller has a connection for the antenna at the back of the controller. It is important to not that the antenna cable should be routed and secured such that the lowest point of the cable is below the cable gland, reducing the possibility that water will run along the cable, into the battery enclosure.

Page 16: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 16 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

Figure 7 – Antenna shown in shipping position (left) and in operating position (right).

If the PCS mounting bracket is also installed on the system then the antenna bracket should sit on-top of the PCS bracket and utilise the same bolts.

6.5 Access & External Cover Panels

The AFB2 must NOT be left unattended without the access panel installed. This is for electrolyte egress containment in the event of failure and rain/dust ingress protection.

The exterior plastic access panels (aka “Avalon Cover Panel”) is shipped and uninstalled and is to be installed when battery is left unattended. Identical panels are installed on both the front and back of the battery. The sheet metal access panel (aka “access panel”) is the removable panel installed on the front of the battery. This panel serves many functions, including safety critical functions and must be fully installed before operating the battery. The access panel is secured via security screws to avoid tampering.

6.6 Mounting External Equipment

Do not attach components to the lower portion of the battery enclosure. The lower section of the AFB2 enclosure serves as secondary containment. This surface MUST NOT be perforated, drilled into, or damaged in any way. Any modification to the lower enclosure will void product warranty.

External equipment including inverter / PCS, DC disconnect and/or antenna may be mounted directly to the AFB2 and depending configuration ordered may already be factory mounted and installed.

Page 17: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 17 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

In event field installation requirements mounting one or more piece of external equipment, a location to mount a bracket for the DC Disconnect and the recommended Ideal Power Converter (if required by project) is provided on the left side of the battery enclosure. There are eight M8 threaded bolt connection points (max 16mm length) provided for this purpose.

If necessary, components may be mounted on the upper portion of the enclosure. This may only be done under the written approval of Avalon Battery. Care must be taken to ensure not to penetrate into components located within the battery. Any penetrations must be sealed completely with a sufficiently weather resistance component, rated NEMA Type 3R or higher.

Page 18: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 18 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

7.0 Equipment Wiring 7.1 Pre-install Requirements

Prior to commissioning the AFB2, local code compliant conduit should be run to the final installation location. A watertight conduit hub or cable gland, of NEMA Type 3R or higher, shall be installed in each of the knockouts in the enclosure that are used for cable passage.

Knockout Location Trade Size Number of

Knockouts Sheet Metal Thickness Intended for Passage of

Left-Hand Side 1-1/4” 1 0.060” [1.5mm] Main DC + Ground Cables

Left-Hand Side 3/4” 1 0.060” [1.5mm] PCS Comm. cables and 24V

supply

Right-Hand Side

Drilled as required N/A 0.060” [1.5mm]

DC connections for unit 2 through 6 within string of up to (6) batteries.

Table 2 – Electrical knock-out details.

An external DC disconnect shall be installed with the battery in some jurisdictions to be able to disconnect the battery from the DC supply or load or external inverter. Disconnect must open all ungrounded conductors and must be readily available and accessible without need of special tools to access or operate. A mounting location is located external to the battery for this purpose as it is recommended that this disconnect be located near to the battery.

Figure 8 – Knockout locations on the AFB2 battery. 1-1/4” and 3/4” knockouts shown on the left, and panel

allocated on the right shown in the middle for any required pass throughs, and the same panel modified to connect with additional batteries shown on the right.

7.2 Mounting the Inverter/PCS Depending upon the battery configuration ordered, it may be required to install the inverter/PCS in the field. In such case, an inverter specific mounting bracket must be first installed on the battery, either ordered as part of a factory configuration or field installed. Refer to PCS and AC battery installation for detailed instructions on installation.

Page 19: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 19 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

Figure 9 – PCS mounting bracket, installed.

7.3 Power / HVDC Connection If required by configuration, main HVDC and protective earth (PE) connections to the AFB2 are made thru the distribution blocks located at the lower left side of the upper enclosure. The HVDC landing distribution block is shown in Figure 10, where the positive connection is shown passed through to the fuse of the battery.

Figure 10 – Main HVDC landing Distribution Block.

Page 20: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 20 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

Figure 11 – Main DC connection label to system

The PE wiring is to land on the ground terminal on the stack rail, as shown in Figure 12. The PE wire is to be routed behind the stack rail, as shown in the left image of Figure 12, in order to allow the stack to be removed without having to disconnect the PE wire. These same connection points are where battery 2 through 6 will have their HVDC and ground wiring landed for multi-battery arrays of up to 6.

Figure 12 – Groud terminal for PE wiring. Note correct routing of PE wire is behind the stack rail (shown on left), in order to allow stack to be removed for servicing. Routing

the PE wire over the stack rail (shown on right) will require removal of PE during stack servicing, posing a potential safety risk.

Wire Cable Size Wire Type Torque Tightening Tool

HVDC (+) 4 to 10 AWG 75°C, Copper

4 to 6 AWG: 45 lb-in 8 to 10 AWG: 35 lb-in

Flat head screwdriver

HVDC (-) 4 to 10 AWG 75°C, Copper

4 to 6 AWG: 35 lb-in 8 AWG: 25 lb-in 10 AWG: 20 lb-in

Flat head screwdriver

PE 8 AWG

Copper 125 lb-in 8 mm hex drive

Table 3 – DC connection wire details.

Page 21: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 21 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

7.4 Service Bracket The service bracket provides connection points for the following:

1. Battery enable switch; must be in enabled position to operate battery 2. PCS 24V input power supply connection; required for battery directly connected to a

PCS/inverter 3. PCS RS-485 communication connection; also required for battery directly connected

to a PCS/inverter 4. RS-232 service connection

Items 2 and 3 are available as a single optional connector from Avalon Battery (PN 00357).

7.5 Communication The AFB2 has two methods of communication for external control and monitoring: Wirelessly over a Zigbee connection, or over a RS-232 wired connection. The primary connection for control and monitoring purposes is wirelessly via Zigbee (note: this requires a Zigbee-enabled battery configuration). A service and commissioning connection is provided through a standard RS-232 D-sub 9 cable. Connection for this communication port is at the battery service access panel shown in Figure 13. Refer to Avalon Communication Specification for more details on communicating with the battery over these interfaces. There are two examples of communication interconnections shown in Appendix B.

Figure 13 – Service bracket showing the RS-232 Communciation port connection

point.

7.6 Batteries in Parallel A battery bank is defined as one to six batteries connected to the same inverter. Battery banks are intended to be wired in parallel via passing wires from a common landing point thru the enclosure of adjacent batteries. The benefit of this method is a reduced requirement for external conduit. The positive, negative and ground wires for batteries 2 through 6 will be sourced from the HVDC distribution block and the PE landing points from battery 1, as discussed in section 7.3. Alternatively, external conduit can be run if so desired. A schematic of this arrangement is available in Appendices B and C.

Page 22: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 22 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

8.0 Installation Checklist The following items are to be inspected and checked during the installation of the AFB2.

Checklist Section Complete Confirm Installation and Operation Manual was supplied and understood by installers

Record state of shock and tilt indicators on packaging

Remove access panel

Confirm tank electrolyte levels are equal

Inspect balance line for any high points more than 3cm above the flat surface of the tank.

Inspect hose and fittings for any damage

Confirm that the protective terminal covers on LVDC wiring at the stack and DC-DC converters

Confirm wiring between stack and DC-DC converters are installed and properly torqued

Check that HVDC plugs are firmly plugged into the DC-DC converters

Confirm that HVDC wiring is installed into distribution block and fuse is properly seated

Inspect all wiring for any foreign materials or conductive material near the terminals or wiring path, confirm no damage to installation

Confirm continuity between grounding lug and system PE

Battery enable switch is in ENABLE position

Confirm Zigbee antenna is installed in the vertical position (if applicable)

Confirm that the Electrical Safety Test & High Voltage Danger labels are installed next to the distribution block.

Remove loose tools or debris located in the enclosure

Install air ducting

Install and secure access

Install plastic Avalon cover panel Table 4 – Installation checklist.

Page 23: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 23 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

9.0 Operation

The AFB2 must NOT be left unattended without the access panel installed. This is for electrolyte egress containment in the event of failure and rain/dust ingress protection.

For operation, the AFB2 is able to be commanded thru one of various control points. This includes a serially or Zigbee enabled PC or energy management system. Refer to Avalon communication spec for details on what parameters and data is available via these communication ports.

9.1 Control Modes The AFB2 possess two control modes: current source / sink and voltage source. Those modes are briefly described below but refer to detailed implementation specification for how to fully facilitate and configure the battery for optimized operation.

9.1.1 Current Mode In current source mode, the battery synchronizes with the connected DC voltage, provided voltage is in accordance with specifications and can source or sink current within limits according to communicated power request. In this mode the AFB2 will actively control output to ensure target is met within present limits. In event battery cannot achieve requested set point, battery will operate at nearest acceptable power level. In current control mode, a default command timeout of 5 minutes will prevent continuous operation without continuous commands.

9.1.2 Voltage Mode In voltage source mode, the battery controls its output DC voltage and will source or sink current to ensure voltage level is maintained based upon load or source connected to the same DC bus. In event load or source exceeds real time capabilities of the battery, the battery will fault and output voltage will cease from the battery.

Page 24: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 24 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

Appendix A – Example Site Interface Drawing

Page 25: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 25 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

Page 26: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 26 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

Appendix B – External Power Connection Diagrams

Page 27: PRODUCT / MODEL NUMBER AFB2€¦ · The Avalon AFB2 Vanadium Flow Battery is an integrated energy storage system designed for power and energy management. The AFB2 is comprised of

DOCUMENT NUMBER: LIFECYCLE REVISION: PAGE: SPC00138 ISSUED 004 27 of 27

TITLE Installation and Operation Manual, DC Battery

THIS DOCUMENT IS VALID ONLY AT TIME OF PRINTING. ANY COPIES MADE ARE CONSIDERED UNCONTROLLED UNLESS STAMPED OTHERWISE IN RED. Printed on: Tuesday, July 10, 2018

Commercial Confidential

Document History and Approvals Revision History

Rev CO Description Revised by Date 001 First release for distribution T. Barrie 2017-Sept-29 002 Update of Power Portal screens T. Barrie 2017-Nov-27

003 Update NX comments and engineering feedback N. Barrett 2018-Apr-12

Approval Record Name Date

Author Nathan Barrett 2018-Apr-12 Reviewed by B. Adams 2018-Apr-17 Reviewed by Approved by Approved by